Method and apparatus for forming subterranean structures

ABSTRACT

A multi-section shield incorporates means for subterranean excavation and conveyance of excavated materials and provides for the installation of the lining planks within the shield. This apparatus is employed in a system of tunnel or conduit lining wherein floor and roof planks are prepositioned and side wall planks are wedged in place therebetween. The method of tunnel or conduit formation herein involved provides for the installation of lining within a shield, and for subsequent advance of the shield.

United States Patent [191 Cunningham [54] METHOD AND APPARATUS FOR FORMING SUBTERRANEAN STRUCTURES [76] Inventor: Vernon Cunningham, PO. Box

9337 Springhill Station, South Charleston, W. Va.

[22] Filed: May 5, 1970 [21] Appl. No; 46,566

Related US. Application Data [62] Division of Ser No. 823,407, May 9, 1969, Pat. No.

[52] U.S. C1. ..61/85, 61/45 R [51] Int. Cl. ..E21d 11/00 [58] Field of Search 61/85, 84, 45, 42, 63, 45 C; 299/31,33,70

[56] References Cited UNITED STATES PATENTS 992,813 /1911 Shepard ..61/45 C 3,404,535 /1968 Tabor ..61/85 3,427,813 2/1969 Hayes ..61/

992,813 5/1911 Shepard ..61/ 1,098,961 6/1914 Mosher ..61/ 1,484,188 2/1924 ORourke ..61/84 2,149,345 3/1939 Hunsaker ..61/84 X 1 Jan. 23, 1973 3,469,884 9/1969 3,578,809 5/1971 Cunningham ..61/85 FOREIGN PATENTS OR APPLICATlONS 167,479 l/l Austria 1.61/45 C 245,438 4/1912 Germany 466,808 10/1928 Germany 608,528 l/l935 Germany 814,871 9/1951 Germany ..61/45 C Primary Examiner-Dennis L. Taylor AttorneyRobert G. McMorrow [57] ABSTRACT A multi-section shield incorporates means for subterranean excavation and conveyance of excavated materials and provides for the installation of the lining planks within the shield. This apparatus is employed in a system of tunnel or conduit lining wherein floor and roof planks are prepositioned and side wall planks are wedged in place therebetween.

The method of tunnel or conduit formation herein involved provides for the installation of lining within a shield, and for subsequent advance of the shield.

1 Claim, 8 Drawing Figures PATENTEUJAN 23 I975 SHEET S []F 5 METHOD AND APPARATUS FOR FORMING SUBTERRANEAN STRUCTURES CROSS REFERENCE TO RELATED APPLICATION This application is a division of my prior, copending application Ser. No. 823,407, now US. Pat. No. 3,578,809 filed May 9,1969.

BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to the formation of subterranean tunnels, conduits and other excavations of the type needed illustratively for sewer lines, in mining, and the like. More specifically, the invention comprehends new and novel equipment, and a related method, for safely and speedily forming subterranean earth openings.

2. Statement of the Prior Art It has heretofore been proposed to employ a shield or encasement with an associated conveyer in the formation of subterranean openings. Such prior devices, often including separable conveyers, digging mechanisms and shields, are shown by way of example in the following patents: I

SUMMARY OF THE INVENTION This invention relates to that category of tunneling apparatus wherein a shield is forced into the tunneling area, the shield being associated with excavation equipment and conveying means. The present apparatus provides a new and novel means for installation of lining timbers within the shield, and for advance of the shield with respect to the previously installed stand or course thereof, employing said previous stand or course as a base for the advancing mechanism. It is a basic objective of this invention to provide a method and related apparatus for the safe, rapid and economical formation and lining of subterranean tunnels, accomplished through the use of self-contained excavation, conveying and shield means, in which the tunnel lining is prepositioned within the shield. By virtue of the installation of an effective liner within the confines of the shield, there is no section of tunneling exposed to the possibility of cave-ins, dislodgement of large rocks or the like, or other similar mishaps.

A further and related objective of importance accomplished by this invention concernsthe provision of a lining system employing planks or timbers which include elongated, substantially rectangular side and base planks, and top planks with slotted corner portions in which the opposite side planks are simultaneously wedged by the application of expansive pressure adjacent the base plank. The apparatus involves elevation means for raising the top planks and for retaining them in elevated location preparatory to installation of the side planks.

This invention comprehcnds a shield assembly, which, when placed in an initially formed excavation, is thereafter self advancing as formation of a tunnel progresses. In accomplishing this objective, the shield comprises leading and trailing sections, the leading section having the excavation apparatus, and the trailing section being used as an assembly area for the tunnel lining, Extensible means in the form of a group of spaced apart jacks or the like are positioned medially within the shield and have portions adapted to bear against the lining. Upon extensions of these jacks, the shield assembly is advanced with respect thereto, thus providing a space for the positioning of further stands or course thereof.

By virtue of the employment of spaced apart, individually actuable jack means, the path of movement of the shield is controllable, thereby enabling the operator to maintain a selected course and to readily correct for deviations.

The excavation apparatus hereof, which may take numerous alternative forms and cover various locations, is preferable and ideally located on the roof section of the leading portion of the shield, immediately over a conveyance area. By this means the excavated material is effectively discharged, and the space within the shield is conserved.

The present invention, useful in the formation of any type of underground opening, such as a tunnel, conduit, or the like, is adaptable for use in the formation of an initial opening which is later converted, as by the introduction of pipe and grouting to other forms, or alternatively, the opening, employing suitably creosoted or treated timbers, may form a completed subterranean structure usable asa vehicular tunnel, or to form an opening to an underground seam of material to be mined. The invention, in essence, relates to a unique method and apparatus for the formation of said openings.

The shield is formed of heavy material, and is provided with a forward cutting edge aiding in the advance thereof.

Additional objects and advantages of the invention include the incorporation of a self-contained conveyer means for the removal of excavated material from within the shield during operation, and the provision of an inclined leading end plate which effectively transfers material to the conveyor means.

Other and further objects and advantages of the invention will become apparent to those skilled in the art from a consideration of the following specification when read in conjunction with the annexed drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an elevational view, partially broken away for disclosure of details, of apparatus of this invention employed in the interrelated method of forming a subterranean tunnel;

FIG. 2 is an enlarged transverse sectional view taken on the line 2-2 of FIG. 1, looking in the direction of the arrows;

FIG. 3 is a further sectional view taken on line 3-3 of FIG. 2, looking in the direction of the arrows;

FIG. 4 is a sectional view on line 4-4 of FIG. 3, showing the upper inside portion of the assembly as seen from below;

FIG. 5 is a cross sectional view on line 5-5 of FIG. 3, showing the lower portion of the assembly;

FIG. 6 is a disassembled perspective view of an elevating apparatus sub-assembly hereof;

FIG. 7 is an illustration of the manner of placement of side timbers in the practice of the method; and

FIG. 8 is a transverse view in section of a completed tunnel.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The environment of employment of the present invention will be understood to be somewhat variable. In some circumstances of use, tunneling excavations are instituted on angular gradients commencing at ground level, while in other circumstances, straight tunneling from a preformed vertical entry bore is desired. In either event, for purposes of description herein, it will be assumed that a section of tunnel has been formed in the ground by whatever means has been dictated by the situation present, and that the apparatus hereof has been assembled and is in place within this preformed tunnel section.

In FIG. 1, the apparatus 20 of this invention is seen in use in the practice of the related method. The apparatus is disposed in the tunnel T in that view, a portion of which has been timbered as will be described below, and a further portion of which is excavated, but not lined. The apparatus is movable forwardly toward the unexcavated area E.

An important and major component of the invention is an enlarged shield 22 formed of heavy metal of the type often employed as armor plating. The shield is here shown in a preferred, rectangular form, but may be polygonal in configuration where tunneling requirements so dictate. As shown in FIGS. 1 and 3, the shield 22 includes a leading section, an intermediate section, and a trailing section. The leading section has a top wall 24, a base wall 26, and side walls 28 and 30. The top wall 24 is elongated, and has a leading edge 32 which is extended forwardly of the corresponding front edge 34 of the base wall. An interior reinforcing plate 36 joins the leading edge 32 and declines angularly inward therefrom, having a flange 38 at its connection with the inside of the top wall. In like manner, the side walls 28 and 30 have plates 40, 42, respectively, which form sharp leading edges therewith and are inclined from said edges to flanges 44, 46.

At a location spaced inwardly from the leading edges of the walls, a series of channel members collectively identified by reference numeral 48 extend about the inside of the walls and are fixedly secured in place, forming an intermediate brace and support extending about the full interior circumference. The channel members 48 define the interior limits ofthe leading section of the shield. The top, side and base walls extend over the intermediate section, and terminate at an interior top flange 50, at a base flange 52, and at side flanges 54, 56, respectively. Each of the flanges has a rebent, retaining and reinforcing member 58 thereon.

In FIGS. 3 and 5 a plate system for directing excavated material to a conveyer hereof is shown. An inclined plate 60 extends from the forward edge 34 of the base wall 26 and has a generally triangular form with a rectangular slot 62 formed at its trailing apex portion within the intermediate section. Secured on the plate over the edge 34 is a reinforcing bar 64 with a leading edge 66 which aids in the movement of the shield through the ground. The plate system further includes vertical guide plates 68 and 70 flxed to the side channel members 48 and to the inner edge of the plate 60. The vertical plates terminate at the end of the slot 62, and parallel upstanding plates 72 and 74 extend rearwardly therefrom at that location. Thus, any material which is forced up the plate 60 is discharged through the slot 62 thereof.

The shield assembly 22 further includes a trailing section 72. Like the previously described sections, the section 76 includes a top wall 78, base wall 80 and side walls 82 and 84. The walls have flanges 86, 88, and 92, respectively. These flanges also have rebent flange sections 94, and the flanges 86, 88, 90 and 92 are respectively fixedly secured to the flanges 50, 52, 54 and 56 of the leading section walls. The respective outer walls are substantially coplanar with one another, and the walls of the trailing section have flat terminal edges uninterupted by flanges or other protruberances, for a purpose made apparent below.

The apparatus hereof includes new and novel selfcontained excavation means. In FIG. 4, it will be noted that the structural members 96 and 98 are extended longitudinally between the flange 50 and the channel member 48 in transversely spaced relation on the top wall 24 in the intermediate section of the shield. A substantially rectangular mounting plate 100 is fixed on the structural members, and has a central swivel plate 102 with curvilinear slots 104, 106 formed therein. These slots receive upstanding connection portions of side-by-side swivel members 108, 110. The members 110 have a fixed extension 112 projecting from one side thereof. A hydraulic cylinder 114 is pivotally connected to the rigidifying member 58 of the top wall, and has an extendable and retractable rod 116 pivotally connected to the extension 112. Suitable fluid supply lines are provided and extend to a control bank or panel 118 shown in FIG. 5. These supply lines, and the control connections therefor, are variable and have therefore been omitted from the drawings for clarity of disclosure. As will be apparent, extension and retraction of the member 116 effects a swivel movement of the members 108, 110 within the limits of the slots 102, 104.

A normally substantially vertical boom 120 is pivotally secured between the members 108, 110 on a pivot pin 122. A second hydraulic cylinder 124 is pivoted between said members at the opposite ends on a pivot 126, and the cylinder has an extensible and retractable rod 128. A pair of enlarged boom plates 130, 132 are fixedly secured to the distal end of the boom 120 on opposite sides thereof, and the rod 128 is pivotally connected between the plates at 132. An elongated arm 136 is pivoted between the boom plates at the ends thereof adjacent the leading shield section, at 138. A third hydraulic cylinder 140 is pivotally mounted between the plates on pivot 142, and its extensible and retractable member 144 is connected between a pair of arm plates 146, 148. A hoe, comprising a flat blade arranged perpendicularly with respect to the longitudinal extent of the arm 136 is flxedly mounted on its outer end, and has rigidifying or reinforcing gussets of appropriate design. As will be understood from the foregoing, the extension and retraction of rod 128 moves the boom and arm forwardly and rearwardly, and the extension and retraction of rod 144 of cylinder 140 results in generally vertical digging strokes of the hoe. In FIG. 3, it will be noted that downstrokes of the hoe against the material E to be excavated will result in a deposit of loosened material on the inclined plate 60.

To convey the excavated material for discharge on mine cars M or other removal means, the invention provides a conveyance system generally identified by reference 152. The conveyer in this form of the invention includes a frame having sides 154, 156 and a horizontal support plate 158. A series of jacks 160 are secured to the frame sides at appropriate locations and t are adjusted such that the frame is inclined upwardly from front-to-rear. The conveyer further includes an endless chain 162 with a series of spaced cross bars 164 which serve to push material placed on the conveyer to its discharge end. The chain is trained about a sprocket on a cross axle 166, mounted on the underside of the plate 60 adjacent to the slot 62 at one end, and at the discharge end of the conveyer about a drive sprocket on an axial 168 driven by a motor 170. The excavated material E is pushed up the plate 60, through the slot 62, and from there onto the conveyer. It is pushed up the conveyer by the cross pieces to the discharge end thereof and into the car M.

As stated above, it has been assumed for purposes of description herein that an initial tunnel excavation has been accomplished prior to the instituion of use of this apparatus and its method of forming and lining a tunnel. As a shield is placed in use, and advanced a measurable distance, for example, about six feet, a lining procedure is instituted. This procedure involves initially the laying in place a group of transverse base timbers 1 72 which rest on the base wall 80 of the trailing section of the shield.

A pair of elevator assemblies 174, best shown in FIG. 6, are employed next in the method. These assemblies 174, which are identical to one another except as to positioning, are each mounted on a vertical channel member 176. One such channel member is'secured between the rebent portions 94 of the top and base walls 86, 88 of the trailing section top and base walls, adjacent the opposite sides thereof, whereby an assembly 174 is provided at each side of the shield. Fixed to the channel 176 is an outer channel 178 having a vertical slot 180 extending from substantially its midsection length to its top. A boss 182 is provided at the base end of the outer channel, and a hydraulic cylinder 184 is connected'thereto. The cylinder has an extensible and retractable rod 186, and is of course supplied with suitable supply lines leading to the control bank 118. The rod l86.has a clevis- 188 on its outer end on which an elongated arm 190 is mounted. The arm 190 has a rectangular block 192 at one end thereof which is dimensioned tobe slidable within the outer channel 178, but is too great in size to pass through the slot 180. The arm 190 extends through the slot, whereby upon extension and retraction of the rod 186, the arm is raised and lowered. The control means for the elevation assembly ispreferably arranged for simultaneous extension andretraction ofeach assembly. As a second step in the method hereof, a group of roof or rafter timbers 194, each having slotted lower corners 196 are placed on the arm and elevated into position above the previously placed base timbers 172, as shown in FIG. 3.

With the roof timbers 194 elevated to a position in which they bear against the top wall 78 of the trailing shield section, and the base timbers in place therebetween, side timbers 198, 200 are forced into position. The side timbers are first positioned angularly in opposite pairs, with their upper ends being located in the slotted ends 196 of the roof timbers. A portable hydraulic cylinder 202 with an extensible member 204 is then employed to substantially simultaneously wedge the base ends of the side timbers into place. This frictionally engages the side timbers between the base and roof timbers, and the timbers are, of course, dimensioned for an extremely rigid connection. This procedure is best illustrated in FIG. 7 of the drawing.

The result of completion of the aforesaid process of timber placement results in the formation of tunnel lining or a completed conduit, up to a final course or stand of timbers disposed within the trailing shield section and indicated in the drawing at S. This final course of timbers coacts with the invention apparatus in providing means for advance of the shield. At convenient peripherally spaced positions, a series of push cylinders or jacks 204 are fixed in brackets 206 on the respective walls of the intermediate section of the shield. In FIG. 2, it will be observed that these may be, in the rectangular form of the invention herein shown, at the four corners of the device, with a center thrust cylinder positioned on the base. Each of said cylinders has an extensible and retractable rod 208 associated therewith and extended through suitable openings in the abutting flanges of the intermediate and trailing sections of the shield. Each of said rods has an abutment collar 210 which is engageable against the course S. The lining is, of course, inmovable due to its manner of formation and also the fact that it is anchored at its terminal by suitable jack means or otherwise. .Ioint extension of all of the rods 208 therefore results in straight linear movement of the shield forwardly into the earth. E. If one or more of the rods is not actuated with the others, the direction of movement is altered, thereby permitting a steering or course alteration of the manner of movement of the shield.

FIG. 8 of the drawing shows, in a non-limiting example, one illustrative end use of the system. There, after installation of the timbers according to the invention, a concrete cradle is first poured over the base timbers. A pipe is positioned in the cradle, and a suitable grout fill employed to fill the void space between the pipe and the side and top timbers. Alternatively, if treated timbers are employed, the conduit formed in the practice of the method may be used as is.

lclaim:

l. A method of forming subterranean lined openings in conjunction with the excavation of the opening, wherein a tunnel shield is advanced in the direction of excavation, the shield having a leading portion with excavation means and means for conveyance of ex cavated material therein and having a trailing liner installation section including a floor, roof, and sides, the method comprising the steps of:

tained in said overhead position within the shield trailing section;

the side timbers including lower ends slanted inwardly toward one another and resting on the base planks;

applying an expansive force between the lower ends of the pairs of said timbers to force the side timbers into substantially vertical supporting positions between the base planks and rafter timbers; and

advancing the shield forwardly of the completed lined opening. 

1. A method of forming subterranean lined openings in conjunction with the excavation of the opening, wherein a tunnel shield is advanced in the direction of excavation, the shield having a leading portion with excavation means and means for conveyance of excavated material therein and having a trailing liner installation section including a floor, roof, and sides, the method comprising the steps of: arranging in sequence base planks on the floor of the trailing section within the shield in abutting relationship and extending transversely of the direction of excavation; positioning rafter timbers against the roof of the trailing section within the shield in abutting relationship and in overhead alignment with the base planks; positioning a pair of side timbers in initial slant position contacting the opposite corners of the respective aligned roof timbers and the base planks whereby the rafter timbers are temporarily maintained in said overhead position within the shield trailing section; the side timbers including lower ends slanted inwardly toward one another and resting on the base planks; applying an expansive force between the lower ends of the pairs of said timbers to force the side timbers into substantially vertical supporting positions between the base planks and rafter timbers; and advancing the shield forwardly of the completed lined opening. 